Survey‐based spreadsheet model on lean implementation

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PurposeThis research was conducted to study benefits of a concept, known as lean manufacturing, which elicits organizations to do more with less effort, time, space, and equipment by eliminating waste. Because lean implementation involves finances, dedication, and cultural change in business, there is a need to assess a company's lean initiative.Design/methodology/approachA comprehensive lean assessment tool is designed targeted for use by manufacturing companies. Research of lean principles and practices was conducted through lean organizations, trade publications, manufacturing web sites, professional articles, textbooks, lean exhibitions, and non‐profit lean organizations.FindingsThis led to the development of a lean survey questionnaire delivered to 143 lean companies and lean consultants for authentic input. Based on the response, survey participation met a goal of 95 percent accuracy with 15 percent error. Completed surveys were compiled and analyzed for fundamental practices of lean organizations. Answers to the survey were assigned numerical values based on lean significance, and a lean assessment model was developed based on Excel. The lean assessment model was fine‐tuned and programmed to output a numerical and descriptive lean assessment grade. It was tested for soundness by inputting mock lean and traditional company answers into the model. Output results from the model correlated with the input.Originality/valueLean thinking philosophy and lean manufacturing methods and principles were exhaustively researched to make a successful lean organization. The research led to the development of a visual indicator, the Lean Thinking Management Wheel. This model to assess lean thinking manufacturing initiatives unique and has a great potential to use industry wide.